Wilkerson R120 Series Installation and maintenance instructions

Introduction
Follow these instructions when installing, operating, or servicing the
product.
Application Limits
These products are intended for use in general purpose compressed
media systems only.
Operating Pressure:
kPa PSIG bar
Maximum Inlet Pressure 2068 300 21.0
Ambient Temperature Range: 40°F to 125°F (4°C to 52°C)
Symbols
Installation
1. The regulator should be installed with reasonable accessibility for
service whenever possible - repair service kits are available. Keep
pipe and tubing lengths to a minimum with inside clean and free of
dirt and chips. Pipe joint compound should be used sparingly and
applied only to the male pipe - never into the female port. Do not use
PTFE tape to seal pipe joints - pieces have a tendency to break off
and lodge inside unit, possibly causing malfunction.
2. Install regulator so that media flow is in the direction of arrow.
Installation must be upstream (high pressure) side and as close to
the devices it is to service (valve, cylinder, tool, etc.). Mounting may
be in any position.
3. Gauge ports are located on both sides of the regulator body for your
convenience. It is necessary to install a gauge or pipe plugs into each
port during installation.
4. For protection against rust, pipe scale, and other foreign matter, install
a filter on the upstream (high pressure) side as close to the regulator
as possible.
Operation
1. Before turning on the media source turn the T-handle counterclockwise
until compression is released from the Control Spring. Then turn on
media source and adjust regulator to desired secondary pressure by
turning T-handle clockwise. This permits pressure to build up slowly,
preventing any unexpected operation of the valve, cylinders, tools,
etc., attached to the line. Adjustment to desired secondary pressure
can be made only with primary pressure applied to the regulator.
2. To decrease regulator pressure setting, always reset from a pressure
lower than the final setting desired. For example, lowering the
secondary pressure from 550 to 410 kPa (80 to 60 PSIG) is best
accomplished by dropping the secondary pressure to 350 kPa (50
PSIG), then adjusting upward to 410 kPa (60 PSIG). Tighten the
Locking Nut on the T-handle to lock the pressure setting.
Reduced Pressure Spring Ranges
“M” Range = 1 – 25 PSI (1/4", 3/8", 1/2" Only)
“L” Range = 2 – 60 PSI (1/4", 3/8", 1/2" Only)
“Standard” Range = 2 – 125 PSI (ALL)
“H” Range = 5 – 250 PSI (ALL)
Installation & Service Instructions
IS-R120
R120, 1/4", 3/8", 1/2", 3/4", 1",
1-1/4", 1-1/2" Series Regulators
ISSUED: July, 2015
Doc. #ISR120, EN #140731, REV -
Richland, Michigan 49083
269-629-5000
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Relieving Regulator
Adjustable
Non-Relieving Regulator
Adjustable
WARNING
To avoid unpredictable system behavior that can cause personal
injury and property damage:
• Disconnect electrical supply (when necessary) before installation,
servicing, or conversion.
• Disconnect air supply and depressurize all air lines connected
to this product before installation, servicing, or conversion.
• Operate within the manufacturer’s specified pressure,
temperature, and other conditions listed in these instructions.
• Medium must be moisture-free if ambient temperature is below
freezing.
• Service according to procedures listed in these instructions.
• Installation, service, and conversion of these products must be
performed by knowledgeable personnel who understand how
pneumatic products are to be applied.
• After installation, servicing, or conversion, air and electrical
supplies (when necessary) should be connected and the product
tested for proper function and leakage. If audible leakage is
present, or the product does not operate properly, do not put
into use.
• Warnings and specifications on the product should not be
covered by paint, etc. If masking is not possible, contact your
local representative for replacement labels.
WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF
THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR
RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND
PROPERTY DAMAGE.
This document and other information from The Company, its subsidiaries
and authorized distributors provide product and/or system options for
further investigation by users having technical expertise. It is important
that you analyze all aspects of your application, including consequences of
any failure and review the information concerning the product or systems
in the current product catalog. Due to the variety of operating conditions
and applications for these products or systems, the user, through its own
analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and
warning requirements of the application are met.
The products described herein, including without limitation, product
features, specifications, designs, availability and pricing, are subject
to change by The Company and its subsidiaries at any time without
notice.
EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR
INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE
THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE.
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Safety Guide
For more complete information on recommended application
guidelines, see the Safety Guide section of Pneumatic Division
catalogs or you can download the Pneumatic Division Safety
Guide at: www.parker.com/safety
WARNING
Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.
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Service
Caution: Disconnect or shut off air supply and exhaust the
primary and secondary pressures before servicing unit.Turning
the T-handle counterclockwise does not vent downstream
pressure on non-relieving regulators. Downstream pressure
must be vented before servicing regulator.
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R120, 1/4", 3/8", 1/2", 3/4", 1", 1-1/4", 1-1/2" Series Regulators IS-R120
Lightly grease with provided lubricant.
Inspect for nicks, scratches, and surface imperfections. If present, reduced
service life is probable and future replacement should be planned.
Clean with lint-free cloth.
5. Lubricate Bottom Plug O-ring and install it in o-ring groove on Bottom
Plug. Be sure Inner Valve Stem fits into center area of Diaphragm
Assembly before installing Bottom Plug. Then screw Bottom Plug into
Body until it bottoms out in body. Tighten to 3.5 to 5.1 Nm (35 to 45 in.
lb.).
6. Turn on media source and adjust to desired secondary pressure as
described in the Operation section. Check regulator for leakage. If
leakage occurs, DO NOT OPERATE — conduct repairs again.
If you have questions concerning how to service this unit, contact your
local authorized dealer or your customer service representative.
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T-handle Adjusting Screw
Lock Nut
Spring Button
Control Spring
Spring, Bottom
Diaphragm Assembly
(Includes Upper Diaphragm Plate
& Lower Diaphragm Button
Inner Valve
Assembly
Body
Bottom Plug
O-ring
Spring Cage (Bonnet) - Torque:
1/4", 3/8", 1/2" – 2.3 to 4.5 Nm
(20 to 40 in. lb.)
3/4", 1-1/4", 1-1/2" – 6.8 to 7.9 Nm
(60 to 70 in. lb.)
Bottom Plug - Torque:
3.9 to 5.1 Nm
(
35 to 45 in. lb.
)
Caution: Grease packets are supplied with kits for lubrication
of seals. Use only mineral based grease or oils. Do not use
synthetic oils such as esters. Do not use silicones.
Note: After servicing unit, turn on air supply and adjust regulator to the
desired downstream pressure. Check unit for leaks. If leakage
occurs, do not operate - conduct repairs and retest.
A. Servicing the Bonnet and Diaphragm Assembly
1. Turn the T-handle counterclockwise until the compression is released
from the Pressure Control Spring.
2. Remove Bonnet Mounting Screws, Bonnet Assembly, Pressure
Control Spring and Spring Button. Remove Diaphragm Assembly.
Next, disassemble, clean, and carefully inspect parts for wear and /
or damage. Wipe parts, clean with soapy water or denatured alcohol.
If using compressed air to blow dry, be sure to wear appropriate eye
protection. If replacement is necessary, use parts from service kits.
3. Install Diaphragm Assembly, Pressure Control Spring, Spring Button
as shown below. Then, install Bonnet Assembly to Body with Mounting
Screws and tighten in an alternating or star pattern to the following
torque specifications:
1/4", 3/8", 1/2" 2.3 to 4.5 Nm (20 to 40 in. lb.)
3/4", 1-1/4", 1-1/2" 6.8 to 7.9 Nm (60 to 70 in. lb.)
B. Servicing the Poppet Assembly
1. Exhaust system media pressure as previously described.Then remove
Bottom Plug by unscrewing it from Body. Next, remove Bottom Plug,
O-ring, Bottom Spring and Inner Valve Assembly.
2. Next, disassemble, clean, and carefully inspect parts for wear and /
or damage. If replacement is necessary, use parts from service kits.
3. Lubricate O-ring and sliding surfaces using grease supplied with
service kit.
4. Install parts as shown.
OUT
IN
Check Valve
Assembly
X Option
Reverse Flow
Only
R120 Regulator with X Option Reverse Flow Feature
R120 Regulator with Panel Mount Conversion Kit
R120 Regulator – Relieving
.625 Dia.
(15.8) Ø
Check Nut
Bonnet
Panel Mounting
Nut
Panel Mounting
Washer
Screw & Knob
Assembly
R120 Regulator – Non-Relieving
Service Kits Available
Description Kit Number Regulator Size
Bottom Plug Only
118Y2 1/4", 3/8"
118A2 1/2"
119B2-2 3/4" thru 1-1/2"
Bottom Plug O-ring Only
118Y102 1/4", 3/8"
118A101 1/2"
118B101 3/4" thru 1-1/2"
Mounting Bracket Kit
WSA15Y57 1/4", 3/8"
W18A57 1/2"
W18B57 3/4" thru 1-1/2"
Panel Mount Conversion Kit W4202 1/4", 3/8"
W4204 1/2"
Knob & Hardware Only WPK16Y 1/4", 3/8", 1/2"
Regulator Repair Kit*
(Relieving)
WRK119Y 1/4", 3/8"
WRK119A 1/2"
WRK119A250 1/2" (“H” Range)
WRK119B 3/4", 1"
WRK119D 1-1/4", 1-1/2"
Regulator Repair Kit*
(Non-Relieving)
WRK118Y 1/4", 3/8"
WRK118A 1/2"
WRK118B 3/4", 1"
WRK118D 1-1/4", 1-1/2"
Spring Cage Kit WRKC119Y 1/4", 3/8"
T-handle Kits WTK119A 1/2"
WTK119B 3/4" thru 1-1/2"
Check Valve Assembly for
Reverse Flow Option WSAN263Y116-2 1/4", 3/8", 1/2", 3/4" thru 1-1/2"
Accessories
Gauges
0 to 60 PSI (0 to 4 bar) K4520N14060
0 to 160 PSI (0 to 11 bar) K4520N14160
0 to 300 PSI (0 to 20 bar) K4520N14300